Materials and methods of producing materials for enhancing tactile perception

ABSTRACT

Materials and methods for producing materials to enhance tactile perception, and articles produced from or incorporating such a material. The materials include a substrate having first and second surfaces and surface patterns of texture on the surfaces. The surface patterns include sensitivity pegs having first portions that project from the first surface and second portions that project from the second surface. The first and second portions of the sensitivity peg are axially aligned and extend in opposite directions from each other to enhance tactile perception at the second surface.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/56,302, filed Dec. 8, 2017, the contents of which are incorporatedherein by reference.

BACKGROUND OF THE INVENTION

The present invention generally relates to materials adapted to directlyor indirectly contact the skin of a user and are capable of enhancingtactile perception of the skin, for example, of the hand. The inventionparticularly relates to materials with unique textures derived fromgeometrically designed micro-structures that enhance tactile perceptionof the skin. Tactile perception can be further enhanced by aligning themicro-structures to unique reflexology markers of a user's skin.

Reflexology markers identify areas of the human body connected throughthe nervous system to other parts of human body. These areas alsocontain the greatest density of mechanoreceptors, which are sensoryreceptors that respond to mechanical pressure and distortion that, inturn, enable the skin to detect touch.

The human hand is critical for a variety of tasks and activities ofdaily living as well as activities related to occupational tasks,athletics, recreation, hobbies, etc. The primary purpose of gloves is toprovide hand protection and gripping ability. The protective benefit ofgloves in many instances inhibits the tactile perception necessary toachieve acceptable performance levels.

In view of the above, it can be appreciated that there is an ongoingdesire to identify materials and/or methods of producing materials thatare capable of providing a level of protection while also enhancingtactile perception, particular but not limited to the human hand.Further, there is a need for materials that can be, for example, madeinto articles or applied to articles, including apparel or equipment, asa more effective solution to further enhance tactile perception.

BRIEF DESCRIPTION OF THE INVENTION

The present invention provides materials and methods for producingmaterials that enhance tactile perception, and to articles produced fromor incorporating such a material.

According to one aspect of the invention, a material is provided thatincludes a substrate having first and second surfaces, and first andsecond surface patterns of texture on the first and second surfaces,respectively. The first and second surface patterns comprise sensitivitypegs having first portions that project from the first surface andsecond portions that project from the second surface. The first andsecond portions of the sensitivity peg are axially aligned and extend inopposite directions from each other to enhance tactile perception at thesecond surface.

According to another aspect of the invention, a method of producing amaterial includes providing a substrate having first and secondsurfaces, and using an additive or subtractive process on the first andsecond surfaces to produce first and second surface patterns of textureon the first and second surfaces, respectively. The first and secondsurface patterns comprise sensitivity pegs having first portions thatproject from the first surface and second portions that project from thesecond surface. The first and second portions of the sensitivity peg areaxially aligned and extend in opposite directions from each other toenhance tactile perception at the second surface.

According to another aspect of the invention, a method of producing aglove is provided that includes the use of a three-dimensional (3D)scanner to scan the hand of an individual, and then from the output ofthe scan create a precise personalized glove for the hand thatincorporates surface patterns of texture on interior and exteriorsurfaces of the glove. The surface patterns comprise sensitivity pegsthat correspond to mapping of reflexology markers on the hand. Eachsensitivity peg has exterior and interior portions that project from theexterior and interior surfaces, respectively, of the glove. The exteriorand interior portions of each sensitivity peg are axially aligned andextend in opposite directions from each other to enhance tactileperception at the interior surface. The precise personalized gloveincorporating the sensitivity pegs significantly enhances tactileperception.

Other aspects and advantages of this invention will be appreciated fromthe following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an image of a material that incorporates sensitivity pegs inaccordance with a nonlimiting embodiment of the invention.

FIG. 2 is an image of a glove that includes a material of the type shownin FIG. 1, wherein the glove incorporates sensitivity pegs atreflexology markers appropriate for a golfer in accordance with anonlimiting embodiment of the invention.

FIG. 3 schematically represents a portion of a material in which asensitivity peg has been incorporated into a single-layer substrate inaccordance with a nonlimiting embodiment of the invention.

FIG. 4 schematically represents a portion of a material in which asensitivity peg has been incorporated into a two-layer substrate inaccordance with a nonlimiting embodiment of the invention.

FIG. 5 schematically represents a portion of a material in which asensitivity peg has been incorporated into a three-layer substrate inaccordance with a nonlimiting embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 through 5 depict nonlimiting embodiments of materials 10 adaptedto be directly or indirectly positioned in contact with the skin of auser for the purpose of enhancing tactile perception of the skin. Thematerials 10 described herein comprise a substrate 12 into which atleast one and typically a plurality of sensitivity pegs 14 have beenincorporated.

The materials 10 may be manufactured to produce entire articles orapplied or otherwise incorporated into articles to define oppositesurface regions of the articles. As nonlimiting examples, such articlesinclude equipment and apparel that may be formed of a wide variety ofmaterials, as nonlimiting examples, equipment and apparel fabricatedfrom leather, cotton, polyesters, and various other natural and man-madematerials. FIG. 2 depicts a glove 16 that incorporates pieces orsections of the material 10 of FIG. 1 located at fingertip regions ofthe glove 16. The material 10 preferably defines at least oppositeinterior and exterior surface regions of the glove 16, such as the glovefingertips as shown in FIG. 2. In this example, the fingertips of awearer's hand contact interior surface regions of the glove 16 formed byinner surfaces of the material 10, and opposite surfaces of the material10 are exposed and define exterior surface regions at the fingertips ofthe glove 16, such that only the thickness of the material 10 separatesthe user's fingertips from the environment at the exterior of the glove16. As such, tactile perception at the user's fingertips is transmittedthrough the thickness of the material 10. The material 10 comprisessensitivity pegs (not labeled) that are located so that the particularembodiment of the glove 16 in FIG. 2 is appropriate for use by a golfer.

As depicted by the nonlimiting examples represented in FIGS. 3, 4, and5, the substrate 12 may have a single or multiple-layer construction,such as a construction consisting of a single layer 18 (FIG. 3) or aconstruction consisting of two layers 18 and 20 (FIG. 4) or three layers18, 20, and 22 (FIG. 5) that may be laminated together and formed of thesame material or different materials. Suitable compositions for thesubstrate 12 include, without limitation, leather, any synthetic fiberincluding synthetic fibers of high tensile strength for protective gear,aramid fibers, silicone, resins including tough synthetic resin made bypolymerizing tetrafluoroethylene, nylon, and conductive materials. Incertain embodiments, the substrate 12 may be constructed as atouchscreen sensitive substrate to allow for use of electronicequipment, as nonlimiting examples, touchscreens of tablets and phones.The substrate 12 may be constructed to have a wide range of thicknessesthat are capable of transmitting tactile perception to a user's skin.Preferred but nonlimiting examples of suitable thicknesses for thesubstrate 12 include up to about five millimeters, more typically up toabout three millimeters in thickness, for example, from about onemillimeter to about three millimeters.

The materials 10 shown in FIGS. 1 and 2 have been subjected to one ormore subtractive or additive processes to generate the sensitivity pegs14 that define a surface pattern with texture on its exterior surface 24visible in FIGS. 1 and 2, and preferably also on its interior surface.In the particular embodiments shown in FIGS. 1 and 2, the sensitivitypegs 14 have been created on the surface of the substrate 12 by anadditive manufacturing process, in particular, a UV LED (ultravioletlight emitting diode) printing process using a UV LED printercommercially available from Direct Color Systems Inc., and theparticular pattern and geometric shape of the pegs 14 was generatedusing graphical design software commercially available under the nameCoreIDRAW from the Corel Corporation. It should be understood thatgraphical design software can be utilized to create pegs 14 having anunlimited number of different patterns and geometric shapes.

The sensitivity pegs 14 may be described as micro-structures and mayhave a variety of shapes and formed as a uniform or random pattern onthe substrate 12 with any desired spacing between pegs 14. For purposesof promoting tactile perception, the sensitivity pegs 14 preferablyprotrude at least about 0.25 millimeter from either and preferably bothsurfaces of the substrate 12 and have an aspect ratio greater than two.More generally, a particularly suitable height for the sensitivity pegs14 is believed to be up to about 50% of the thickness of the substrate12. In the nonlimiting example of the substrate 12 of the glove 16 ofFIG. 2 formed from leather having a thickness of about 0.8 mm to 3.0 mm,the sensitivity pegs 14 preferably protrude a distance of about 0.25 to1.5 millimeters. Also, for the purpose of promoting tactile perception,the sensitivity pegs 14 are preferably formed in a pattern in which thepegs 14 are spaced less than five millimeters from each other.

As schematically represented in FIG. 3, a nonlimiting example of asensitivity peg 14 can be formed by a subtractive process, preferablylaser engraving, performed on opposite surfaces 24 and 26 of a substrate12 consisting of a single layer 18. Alternatively, the sensitivity peg14 may be formed by an additive process, preferably UV-LED printing bywhich jetted ink droplets are printed directly onto the surfaces 24 and26 to form the pegs 14. In either case, portions of the peg 14 protrudefrom both surfaces 24 and 26 of the substrate 12. In FIG. 3, the topportion of the sensitivity peg 14 extending from the upper surface 24has a cylindrical shape, which is believed to be a shape particularlyeffective for tasks requiring light gripping. The bottom portion of thesensitivity peg 14 extending from the lower surface 26 has a conicalshape terminating with a point, which is believed to be a shape thatpromotes enhanced tactile perception. As such, the upper and lowersurfaces 24 and 26 would ordinarily be intended as exterior and interiorsurfaces, respectively, of a garment, such as the glove 16 of FIG. 2, inwhich case the exterior upper surface 24 serves as a gripping surfaceand the interior lower surface 26 serves as a tactile surface thatcontacts the user's hand. Both portions of the sensitivity peg 14 act inconcert to enhance tactile perception, whereby sensitivity istransferred through the peg 14 from its upper portion located at thesurface 24 to its lower portion located at the surface 26.

FIG. 4 schematically represents a nonlimiting example of a sensitivitypeg 14 projecting from opposite surfaces 24 and 26 of a laminatedsubstrate 12 consisting of two layers 18 and 20. The upper and lowerportions of the sensitivity peg 14 can be formed from the materials ofthe layers 18 and 20, respectively, using a subtractive process. Anarticle comprising the two-layer substrate 12 is intended to provide agreater level of protection to the user, yet yield an enhanced level oftactile perception as a result of sensitivity being transferred via thepeg 14 from its upper portion to its lower portion through the thicknessof the substrate 12.

FIG. 5 schematically represents a nonlimiting example of a sensitivitypeg 14 projecting from opposite surfaces 24 and 26 of a laminatedsubstrate 12 consisting of three layers 18, 20, and 22. In thisembodiment, the sensitivity peg 14 has been formed on the interior layer22 of the substrate 12 and its upper and lower portions protrude throughperforations formed in the outer layers 18 and 20, respectively. As anonlimiting example, the portions of the peg 14 may be formed by anadditive process that deposits the portions on opposite surfaces of theinterior layer 22 through preexisting perforations formed in the outerlayers 18 and 20, for example, by a laser engraver. To promote thegripping function of the upper surface 24, the upper portion of the peg14 is in the form of a jagged “claw” that projects much farther from theupper surface 24 than the distance that the lower portion of the peg 14projects from the lower surface 26. The integrity of the interior layer22 maintains desired protection characteristics of the substrate 12.Sensitivity is transmitted via the peg 14 from its upper portion to itslower portion through the thickness of the interior layer 22.

In each case of FIGS. 3 through 5, the upper and lower portions of thesensitivity peg 14 are axially aligned and extend in opposite directionsfrom each other, the conical-shaped lower portion of the peg 14projecting from the interior surface 26 of the substrate 12 providestactile perception, for example, as a result of a user's skin contactingthe peg 14, and the upper portion of the peg 14 projecting from theouter layer 18 provides or promotes a gripping capability, for example,if the material 10 forms part of a glove 16 as shown in FIG. 2. Thoughdiscrete and separated by the substrate 12 or one or more layersthereof, the sensitivity pegs 14 are aligned so as to be able totransmit feel and sensitivity from an object being handled with orotherwise contacted by the upper portion of the peg 14 at the outersurface 24 of the substrate 12 to mechanoreceptors of the skincontacting the lower portion of the peg 14 at the inner surface 26 ofthe substrate 12.

By forming a plurality of sensitivity pegs 14 on an article, forexample, as shown in FIG. 2, the resulting textured surface pattern on asurface contacted by a user's skin (e.g., the lower surfaces 26 of FIGS.3-5) enhances tactile perception (feel and sensitivity), and theresulting textured surface pattern on a surface opposite the surfacecontacted by a user's skin (e.g., the upper surfaces 24 of FIGS. 3-5)enhances grip. In the nonlimiting example of the glove 16 of FIG. 2, thematerial 10 can be selectively located on the glove 16 to allow thesensitivity pegs 14 to align with reflexology markers on the hand toenhance feel and sensitivity. The principles of reflexology may beutilized to identify reflexology markers of the hand and align of thematerial 10 with the reflexology marker to promote feel and sensitivityand enhance tactile perception of the hand.

Articles incorporating the material 10 can be customized for anindividual user. For example, the surface pattern, substrate thickness,and location of the material 10 on an article may be customized based onphysiological characteristics of the user and the intended application.As a nonlimiting example, for incorporation into a glove an image of theintended user's hand may be taken to provide a custom fit glove and toalign the surface pattern formed by the sensitivity pegs 14 withreflexology markers of the user's hand to enhance tactile perception. Asa particular but nonlimiting example, a Go!Scan 50™ scanner commerciallyavailable from Creaform Inc., can be used to scan a hand of an intendeduser to generate a 3D model of the hand. The scan data from the 3D modelis then converted to a DXF file that represents a 2D glove pattern. Anappropriate substrate material and substrate thickness is selected withdesign characteristics based on the requirements of the task(s) to beperformed by the user with the glove. Additional design specificationsinclude, but are not limited to, the composition, geometricdesign/shape, and surface pattern of the sensitivity pegs 14. A laserengraver, for example, a 30-Watt model commercially available fromEpilog Laser, is then used to generate the desired pattern(s) of pegs 14in the substrate based on the DXF file representing the 2D glovepattern. The particular size and location of each pattern of pegs 14formed on the substrate can correspond to the locations of thereflexology markers of the intended user's hand A robotic sewing machinemay then be utilized to assemble the substrate and various othercomponents of the glove.

Variations in material properties, for example, without limitation,properties of the substrate 12 and sensitivity pegs 14, may be made toprovide better gripping offered by the outer portions of the pegs 14projecting from the outer surface 24 of the substrate 12, whileenhancing feel and sensitivity transmitted from the outer portions ofthe pegs 14 and through the pegs 14 to the inner portions of the pegs 14projecting from the inner surface 26 of the substrate 12.

In view of the above, the material 10 can be advantageously utilized ina variety of articles, including but not limited to gloves and equipmentused in sports and leisure activities such as golf, football, baseball,soccer, driving, and skiing. Still other nonlimiting applications forthe material 10 include articles for occupational safety, hobby andcraft, household activities, and therapeutic uses.

Methods of fabricating the material 10 include the above-noted laserengraving, laser cutting, and 3D printing techniques performed on atleast one surface of a substrate to generate sensitivity pegs 14 thatproject from the surface to define a surface pattern on the surface, andpreferably are continuous through the substrate to define acomplementary surface pattern on the opposite surface of the substrate.Laser engraving is a technique known to be capable of producingmicro-structures over a wide range of specifications in a wide varietyof materials. Sensitivity peg shapes and surface patterns can be createdwith appropriate software, saved in a computer file, and sent to thelaser used to produce the pegs, offering a knowledge managementcapability that enables the pegs to be safely and efficientlymass-produced.

The above-noted UV-LED printing technique is a type of 3D printingprocess also suitable for forming sensitivity pegs 14 that project fromat least one and preferably opposite surfaces of a substrate to definesurface patterns on the surfaces. UV-LED printing allows for 3Dstructures to be deposited on a variety of substrate materials. Similarto laser engraving, sensitivity peg shapes and surface patterns can becreated with appropriate software, saved in a computer file, and sent tothe UV-LED printer as needed.

Other aspects and advantages of this invention will be furtherappreciated from the nonlimiting embodiments represented in thedrawings.

While the invention has been described in terms of specific orparticular embodiments, it should be apparent that alternatives could beadopted by one skilled in the art. For example, the material 10 and itscomponents could differ in appearance and construction from theembodiments described herein and shown in the drawings, functions ofcertain components of the material 10 could be performed by componentsof different construction but capable of a similar (though notnecessarily equivalent) function, processes could be modified, andappropriate materials could be substituted for those noted. In addition,the invention encompasses additional or alternative embodiments in whichone or more features or aspects of a particular embodiment could beeliminated or two or more features or aspects of different disclosedembodiments may be combined. Accordingly, it should be understood thatthe invention is not necessarily limited to any embodiment describedherein. It should also be understood that the phraseology andterminology employed above are for the purpose of describing theillustrated embodiments, and do not necessarily serve as limitations tothe scope of the invention. Therefore, the scope of the invention is tobe limited only by the following claims.

1. A material comprising: a substrate having first and second surfaces;and first and second surface patterns of texture on the first and secondsurfaces, respectively, the first and second surface patterns comprisingsensitivity pegs having first portions that project from the firstsurface and second portions that project from the second surface, thefirst and second portions of the sensitivity peg being axially alignedand extending in opposite directions from each other to enhance tactileperception at the second surface.
 2. The material according to claim 1,wherein the material is a component of an article used in occupations,sports, hobbies, and household activities.
 3. The material according toclaim 2, wherein the article is a glove.
 4. The material according toclaim 2, wherein the second surface pattern of texture is aligned withreflexology markers on skin of a user of the article to enhance tactileperception of the skin.
 5. The material according to claim 1, whereinthe first portions of the sensitivity pegs project from the firstsurface of the substrate to enhance grip at the first surface.
 6. Thematerial according to claim 1, wherein the substrate comprises a singlelayer.
 7. The material according to claim 1, wherein the substratecomprises multiple layers and the first portions of the sensitivity pegsproject from a first of the multiple layers and extend through a secondof the multiple layers.
 8. The material according to claim 1, whereinthe substrate comprises first and second layers and a third layertherebetween, and the first and second portions of the sensitivity pegsproject from the third layer and extend through each of the first andsecond layers.
 9. The material according to claim 1, wherein thesensitivity pegs are spaced apart less than five millimeters.
 10. Thematerial according to claim 1, wherein the first and second portions ofthe sensitivity pegs each have an aspect ratio of greater than one. 11.A method comprising: providing a substrate having first and secondsurfaces; and using an additive or subtractive process on the first andsecond surfaces to produce first and second surface patterns of textureon the first and second surfaces, respectively, the first and secondsurface patterns comprising sensitivity pegs having first portions thatproject from the first surface and second portions that project from thesecond surface, the first and second portions of the sensitivity pegbeing axially aligned and extending in opposite directions from eachother to enhance tactile perception at the second surface.
 12. Themethod according to claim 11, wherein the additive or subtractiveprocess used is laser engraving.
 13. The method according to claim 11,wherein the additive or subtractive process used is LED printing. 14.The method according to claim 11, further comprising applying thematerial to an article used in occupations, sports, hobbies, andhousehold activities.
 15. The method according to claim 14, wherein thearticle is a glove.
 16. The method according to claim 14, wherein thesecond surface pattern of texture is aligned with reflexology markers onskin of a user of the article to enhance tactile perception of the skin.17. The method according to claim 11, wherein the substrate comprises asingle layer.
 18. The method according to claim 11, wherein thesubstrate comprises multiple layers and the first portions of thesensitivity pegs project from a first of the multiple layers and extendthrough a second of the multiple layers.
 19. The method according toclaim 11, wherein the substrate comprises first and second layers and athird layer therebetween, and the first and second portions of thesensitivity pegs project from the third layer and extend through each ofthe first and second layers.
 20. The method according to claim 11,wherein the sensitivity pegs are spaced apart less than five millimetersand the first and second portions of the sensitivity pegs each have anaspect ratio of greater than one.